US8807993B2 - System and method for the calcination of minerals - Google Patents
System and method for the calcination of minerals Download PDFInfo
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- US8807993B2 US8807993B2 US12/295,468 US29546807A US8807993B2 US 8807993 B2 US8807993 B2 US 8807993B2 US 29546807 A US29546807 A US 29546807A US 8807993 B2 US8807993 B2 US 8807993B2
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- 238000001354 calcination Methods 0.000 title claims abstract description 87
- 229910052500 inorganic mineral Inorganic materials 0.000 title claims abstract description 12
- 239000011707 mineral Substances 0.000 title claims abstract description 12
- 238000000034 method Methods 0.000 title abstract description 60
- 239000008187 granular material Substances 0.000 claims abstract description 157
- 238000012546 transfer Methods 0.000 claims abstract description 43
- 239000002245 particle Substances 0.000 claims abstract description 25
- 239000007787 solid Substances 0.000 claims abstract description 7
- 239000007789 gas Substances 0.000 claims description 121
- 238000006243 chemical reaction Methods 0.000 claims description 92
- 238000010438 heat treatment Methods 0.000 claims description 44
- 239000000463 material Substances 0.000 claims description 42
- 238000002485 combustion reaction Methods 0.000 claims description 29
- 239000000446 fuel Substances 0.000 claims description 16
- 238000009826 distribution Methods 0.000 claims description 12
- 238000012545 processing Methods 0.000 claims description 9
- 238000005086 pumping Methods 0.000 claims description 6
- 230000006870 function Effects 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 5
- 238000000197 pyrolysis Methods 0.000 claims description 5
- 230000001629 suppression Effects 0.000 claims description 4
- 238000009966 trimming Methods 0.000 claims description 4
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 118
- 229910002092 carbon dioxide Inorganic materials 0.000 description 61
- 239000001569 carbon dioxide Substances 0.000 description 57
- 230000008569 process Effects 0.000 description 42
- 239000000047 product Substances 0.000 description 34
- 235000019738 Limestone Nutrition 0.000 description 22
- 239000006028 limestone Substances 0.000 description 22
- 238000002347 injection Methods 0.000 description 17
- 239000007924 injection Substances 0.000 description 17
- 238000013461 design Methods 0.000 description 13
- 238000006555 catalytic reaction Methods 0.000 description 12
- 239000012530 fluid Substances 0.000 description 12
- 239000011435 rock Substances 0.000 description 12
- 230000003197 catalytic effect Effects 0.000 description 11
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 11
- 239000001095 magnesium carbonate Substances 0.000 description 11
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 11
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 10
- 238000013459 approach Methods 0.000 description 10
- 239000000567 combustion gas Substances 0.000 description 10
- 230000000694 effects Effects 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 230000008901 benefit Effects 0.000 description 9
- 235000010755 mineral Nutrition 0.000 description 9
- 238000000926 separation method Methods 0.000 description 9
- 239000000126 substance Substances 0.000 description 9
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 8
- 235000011941 Tilia x europaea Nutrition 0.000 description 8
- 229910052799 carbon Inorganic materials 0.000 description 8
- 239000004571 lime Substances 0.000 description 8
- 235000014380 magnesium carbonate Nutrition 0.000 description 8
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 8
- 239000011148 porous material Substances 0.000 description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- 238000010791 quenching Methods 0.000 description 7
- 230000000171 quenching effect Effects 0.000 description 7
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 6
- 239000000395 magnesium oxide Substances 0.000 description 6
- 239000000376 reactant Substances 0.000 description 6
- 230000009257 reactivity Effects 0.000 description 6
- 238000001179 sorption measurement Methods 0.000 description 6
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 5
- 238000010793 Steam injection (oil industry) Methods 0.000 description 5
- 230000004913 activation Effects 0.000 description 5
- 239000010459 dolomite Substances 0.000 description 5
- 229910000514 dolomite Inorganic materials 0.000 description 5
- 238000000227 grinding Methods 0.000 description 5
- 230000003993 interaction Effects 0.000 description 5
- 229910052757 nitrogen Inorganic materials 0.000 description 5
- 230000009467 reduction Effects 0.000 description 5
- 230000004044 response Effects 0.000 description 5
- 238000000137 annealing Methods 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 238000003339 best practice Methods 0.000 description 4
- 230000007423 decrease Effects 0.000 description 4
- 230000007547 defect Effects 0.000 description 4
- 230000002939 deleterious effect Effects 0.000 description 4
- 230000007613 environmental effect Effects 0.000 description 4
- 230000014509 gene expression Effects 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 238000011068 loading method Methods 0.000 description 4
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 4
- 230000007246 mechanism Effects 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 230000005855 radiation Effects 0.000 description 4
- 230000009919 sequestration Effects 0.000 description 4
- 239000002594 sorbent Substances 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 3
- 238000005452 bending Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 239000003546 flue gas Substances 0.000 description 3
- 238000011010 flushing procedure Methods 0.000 description 3
- 230000037361 pathway Effects 0.000 description 3
- 238000005245 sintering Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 238000002441 X-ray diffraction Methods 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- 238000001311 chemical methods and process Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000018044 dehydration Effects 0.000 description 2
- 238000006297 dehydration reaction Methods 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 239000005431 greenhouse gas Substances 0.000 description 2
- 239000000543 intermediate Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000005065 mining Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229910021532 Calcite Inorganic materials 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- 241001274613 Corvus frugilegus Species 0.000 description 1
- 206010011878 Deafness Diseases 0.000 description 1
- 208000035859 Drug effect increased Diseases 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- 230000001133 acceleration Effects 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000003225 biodiesel Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- NKWPZUCBCARRDP-UHFFFAOYSA-L calcium bicarbonate Chemical class [Ca+2].OC([O-])=O.OC([O-])=O NKWPZUCBCARRDP-UHFFFAOYSA-L 0.000 description 1
- 150000001721 carbon Chemical class 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 229910001748 carbonate mineral Inorganic materials 0.000 description 1
- 238000004523 catalytic cracking Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000001934 delay Effects 0.000 description 1
- 238000004455 differential thermal analysis Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
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- 239000012774 insulation material Substances 0.000 description 1
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- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910021645 metal ion Inorganic materials 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 230000001473 noxious effect Effects 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
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- 230000035484 reaction time Effects 0.000 description 1
- 230000003134 recirculating effect Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000002040 relaxant effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000005201 scrubbing Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
- 239000002918 waste heat Substances 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B1/00—Preliminary treatment of ores or scrap
- C22B1/02—Roasting processes
- C22B1/10—Roasting processes in fluidised form
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J6/00—Heat treatments such as Calcining; Fusing ; Pyrolysis
- B01J6/001—Calcining
- B01J6/004—Calcining using hot gas streams in which the material is moved
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/08—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles
- B01J8/082—Controlling processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/08—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles
- B01J8/087—Heating or cooling the reactor
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B13/00—Oxygen; Ozone; Oxides or hydroxides in general
- C01B13/14—Methods for preparing oxides or hydroxides in general
- C01B13/18—Methods for preparing oxides or hydroxides in general by thermal decomposition of compounds, e.g. of salts or hydroxides
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
- C01F11/00—Compounds of calcium, strontium, or barium
- C01F11/02—Oxides or hydroxides
- C01F11/04—Oxides or hydroxides by thermal decomposition
- C01F11/06—Oxides or hydroxides by thermal decomposition of carbonates
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
- C01F5/00—Compounds of magnesium
- C01F5/02—Magnesia
- C01F5/06—Magnesia by thermal decomposition of magnesium compounds
- C01F5/08—Magnesia by thermal decomposition of magnesium compounds by calcining magnesium hydroxide
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2/00—Lime, magnesia or dolomite
- C04B2/10—Preheating, burning calcining or cooling
- C04B2/12—Preheating, burning calcining or cooling in shaft or vertical furnaces
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B1/00—Shaft or like vertical or substantially vertical furnaces
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B17/00—Furnaces of a kind not covered by any preceding group
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D13/00—Apparatus for preheating charges; Arrangements for preheating charges
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D17/00—Arrangements for using waste heat; Arrangements for using, or disposing of, waste gases
- F27D17/004—Systems for reclaiming waste heat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00017—Controlling the temperature
- B01J2208/00106—Controlling the temperature by indirect heat exchange
- B01J2208/00265—Part of all of the reactants being heated or cooled outside the reactor while recycling
- B01J2208/00292—Part of all of the reactants being heated or cooled outside the reactor while recycling involving reactant solids
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00017—Controlling the temperature
- B01J2208/0053—Controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/40—Production or processing of lime, e.g. limestone regeneration of lime in pulp and sugar mills
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Thermal Sciences (AREA)
- Physics & Mathematics (AREA)
- General Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Ceramic Engineering (AREA)
- Environmental & Geological Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Geochemistry & Mineralogy (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Metallurgy (AREA)
- Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
- Physical Or Chemical Processes And Apparatus (AREA)
- Furnace Details (AREA)
- Feeding, Discharge, Calcimining, Fusing, And Gas-Generation Devices (AREA)
Abstract
Description
-
- Creating the initial conditions of a gas-solid multiphase system.
- Catalysing the reaction to enable the reaction process to be complete within the residence time of the feedstock granules in the system.
- Flushing carbon dioxide from the system so as to minimise the quenching of the reaction.
- Enabling the generation of pure carbon dioxide by condensation and scrubbing from the exhaust gas.
- Dislodging granules from surfaces so as to avoid the build up of granule plugs.
- Providing a source of gas for injection into a flameless distributed heater in order to control the reaction rate at the desired temperature.
-
- (a) the use of steam to catalyse the reaction so that the reaction can be complete within one pass;
- (b) the use of steam to inject the granules into the
reactor 10 and move the granules through the reactor (and later assisted by the reaction gasses); - (c) the use of a reactor tube 17 (selected from a diversity of shapes) with a diameter such that the exhaust velocity of the gases is between 20 and 50 m s−1.
- (d) the use of a
helix 18 of thereactor tube 17 to limit the acceleration of the granules through thereactor 10 by the gas to provide a compact reactor system with the desired granule residence time, a rapid heat transfer between the granules and the gas, and a high surface area for heat transfer to the granules; - (e) the use of the
helix 18 to provide the centrifugal motion that facilitates the separation of the granules from the gases at the gas-granule separator 19. - (f) The use of the
helix 18 to induce a pressure drop through thereactor 10 such that the steam injection pressure at theinjector 16 is high so as to promote the catalytic action of steam, and the pressure of the gas at the exit 21 is low so as to limit the partial pressure of the carbon dioxide and suppress the effect of the back reaction. - (g) the separation of the gases from the granules at a number of stages during the reaction using reactor segments in series so as to reduce the effect of the back reaction, allowing a reduction in the calciner temperature.
- (h) the co-flow arrangement of the gas and granules within the
reactor 10 to support a stable reactor system - (i) a counterflow of the combustion gases in the
external heating system 24 to the gas and granule flow in thetube 17 to achieve the desired temperature distribution in thecalciner reactor 10. - (j) The injection of a fraction of the calciner gas output into the
external heating system 24 to limit the production of carbon in the combustion process. - (k) The use of oxygen instead of air as a combustion gas, or the use of a ceramic within the external heating system to separate the nitrogen and oxygen.
k A(x)=2.02×10−7 S(x)exp(−11.92p/p o)s −1
S(x)=S O(1−x)1.7(1-37 ln(1−x))0.89m2kmol−1
k A(x, T)=k o(x)exp(−E A /RT)s −1
k catalysis =k A+(k B −k A)K ads px/(1+K ads px)
TABLE 1 | |||
Parameter | Value | Units | |
Calciner Properties | |||
Number of Reactor Segments | N | 2 | |
Tube Length per segment | L | 24 | M |
Calciner Diameter | D | 0.30 | M |
Calciner Wall Thickness | δr | 0.0036 | M |
Helical Diameter | Dh | 0.76 | M |
Thermal Conductivity | K | 21.5 | W m−1 K−1 |
Residence Time | τres | <7.5 | S |
Heat Exchange Temperature | Te | 984 | ° C. |
Calciner Gas Pressure-exit | pout | 0.3 | Atm |
Calciner GasPressure- | pin | 1.4 | Atm |
entrance | |||
Feed Stock Properties | |||
Feedstock Rate | γA | 1.45 | kg s−1 |
Feedstock Mesh Size | dA | 50-150 | |
Calciner Charge | |||
10 | Kg | ||
Degree of Reaction | α*□ | >0.98 | |
Superheated Steam Properties | |||
Injection Rate | γsteam | 0.09 kg/s at throat | kg/s |
0.09 kg/s at base | |||
dQ/dt=UA(T e −T c)−γAαΔH calc(T c)+γA C p,reactant(T in −T c)+γsteam C p,steam(T e −T c)
U=1/(1/h e +δr/k30 1/h c)
α*=1−exp(−<kreaction(T c)>*τres)
UA(T e −T c)=γα*ΔHcalc(Tc)
<k reaction(T c)>*τres>>1, so that α≈1.
-
- Substantially reducing the emissions of carbon dioxide from calcination of carbonates compared to conventional calciners by producing essentially pure carbon dioxide from the calcination step, enabling a cost effective means to increase carbon capture for at least about 68% of the total emissions produced using conventional fuels such as LPG for combustion. This substantially pure carbon dioxide can be compressed and used in other industrial processes, or permanently captured by sequestration, without the need for the expensive process step of separation of gases as would be required for carbon capture from conventional calciners. Further, the calcination process can use heat generated from a diversity of sources other than combustion, including the use of steam generated from a solar concentrator or a power plant. In principle, the process could operate with zero carbon dioxide emissions by the combination of using alternative energy sources for heat and sequestration of the pure carbon dioxide produced by calcination.
- Reducing the residence time for feedstock in the calciner to the order of seconds compared to hours for the conventional calciner operating at about 1000° C., through a reactor in which transit time of an average feedstock granule through the reactor is several seconds as a result of the granular flow, and the use of superheated steam as a catalyst and finely ground feedstock that increases the rate of reaction so that the calcination reaction takes place to the desired degree within this transit time. This reduces the size and capital cost of a calciner.
- Reducing the deleterious effect of the quenching of the reaction by carbon dioxide when calcining carbonates, that limits conventional calciners which are heated by combustion within the kiln, by separating the processes of heat generation from calcination by using an external heat source, and making use of the efficient heat transfer to the feedstock granules that results from direct radiative heating of the granules, and indirect heating of the turbulent flow of the gas at the calciner surface and efficient heat transfer from the gas to the granule by virtue of the friction of the granular flow with the gas.
- Reducing the calcination temperature from that required by conventional calciners, as shown by the calcining of limestone at about 925° C. compared to 960-1100° C. for most calciners, by taking advantage of the fast reaction rate and by flushing the carbon dioxide from the calciner by the superheated steam and separators.
- Reducing the response time of the calciner so it is the order of seconds to minutes, so that the process conditions can be adjusted almost instantaneously to meet variations in the Feedstock, or the calcined product specifications; and to allow a standby mode from which processing can commence almost instantly, and to allow a fast turn-on and turn-off of the system with minimal delays and losses of Feedstock. The latter losses would be the order of kilograms, compared to such times in a conventional calciner in which the timescales are hours and the losses of product is tens of tonnes.
- Producing highly reactive calcined products by use of a calciner design in which the residence time is short compared to the time to induce annealing of the products, compared to conventional calciners in which the product reactivity is reduced by the annealing of the products because of the longer residence time. The method can e.g. produce lime super-sorbents from limestone and magnesite super-sorbents from magnesia in a single step.
- Exhibiting small attrition of the calciner walls by operating under a condition in which the volume fraction of Feedstock in the reactor is small such that the attrition mechanism of conventional calciners from the load is not applicable.
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AU2006901658 | 2006-03-31 | ||
AU2006901658A AU2006901658A0 (en) | 2006-03-31 | A method of continusously calcining materials to their oxide form | |
AU2006901994A AU2006901994A0 (en) | 2006-04-18 | Method of carbon capture | |
AU2006901994 | 2006-04-18 | ||
AU2006902293A AU2006902293A0 (en) | 2006-05-03 | Method of carbon capture using the calcination carbonation cycle | |
AU2006902293 | 2006-05-03 | ||
AU2006904553 | 2006-08-22 | ||
AU2006904553A AU2006904553A0 (en) | 2006-08-22 | Semi-dolime cements, fertilizers and sorbents | |
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AUPCT/AU2006/001572 | 2006-10-23 | ||
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AU2007900684A AU2007900684A0 (en) | 2007-02-09 | System And Method For Calcination Of Minerals | |
PCT/AU2007/000424 WO2007112496A1 (en) | 2006-03-31 | 2007-04-02 | System and method for the calcination of minerals |
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BRPI0709913A8 (en) | 2016-07-05 |
BRPI0709913B1 (en) | 2017-04-04 |
WO2007112496A1 (en) | 2007-10-11 |
EP2004319B8 (en) | 2015-07-22 |
AU2007233570A1 (en) | 2007-10-11 |
US20110008227A1 (en) | 2011-01-13 |
BRPI0709913A2 (en) | 2011-07-26 |
US9469884B2 (en) | 2016-10-18 |
EP2004319A1 (en) | 2008-12-24 |
CA2643594A1 (en) | 2007-10-11 |
CA2643594C (en) | 2014-10-14 |
EP2004319A4 (en) | 2011-07-20 |
AU2007233570B2 (en) | 2010-11-18 |
CN101466461A (en) | 2009-06-24 |
CN101466461B (en) | 2012-06-20 |
EP2004319B1 (en) | 2015-06-10 |
US20140348727A1 (en) | 2014-11-27 |
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